Systems and method for hvac air flow increase

ABSTRACT

The method may be a process of increasing the size and placement of return air ducts to increase the efficiency and airflow of a heating and cooling system. The process may take into consideration the current placement and sizes of return air in an existing building or may take into consideration the size of new construction for proper size and placement of return air ducts. The process allows for increased surface area which in turn allows for increased air intake and increased output.

PRIORITY CLAIM AND CROSS-REFERENCE TO RELATED APPLICATION

A claim for priority to the Nov. 12, 2019 filing date of U.S. Provisional Patent Application No 62/934,083 (“the '083 Provisional Application”), titled HVAC AIR FLOW INCREASE is hereby made pursuant to 35 U.S.C. § 119(e). The entire disclosure of the '083 Provisional Application is hereby incorporated herein

TECHNICAL FIELD

This disclosure relates generally to a method of increasing airflow within a heating, ventilation and air conditioning (HVAC) unit. More specifically, this disclosure relates to a modifying existing HVAC systems or installing new systems in both residential and commercial applications with increased airflow.

BACKGROUND

HVAC systems have been utilized in commercial and residential properties for decades. Many of the current HVAC systems include return air flow ducts that allow a system to have air from the interior of the building be pulled into the system and then heated or cooled depending on the desire of the building inhabitant. Many current systems may utilize multiple points to position return air ducts in a building to enhance the performance of the HVAC system and increase air flow within the building as well. The increased airflow allows for a more efficient system that cuts down on heating and cooling costs.

In many buildings return air ducts are positioned one on each floor and the sizes of the return air ducts vary. Additionally most heating and cooling systems have a filter positioned within the system that is at a 90° or even 180° degrees from where the air enters the duct to when the air is filtered in the system and either heated or cooled.

Current systems fail to take advantage of increased surface area for return air ducts to allow for increased airflow and a more efficient system. The following description provides the ability to overcome the shortcomings of current systems and devices.

SUMMARY

A process is intended for increasing efficiency of HVAC systems by providing increased surface area for return air ducts as well as better airflow. The process includes adjusting the angle of airflow as well as the size and placement of return air ducts in a building. The process may include adjusting current HVAC systems or installation of new systems including installation of new ductwork, furnace, air conditioner and grilles. The process may allow the system to increase the airflow but also provide better airflow with better filtration.

According to one aspect, a method for increasing airflow in an HVAC system may include: selecting a furnace with a preexisting return airflow duct, the furnace located in a first room; connecting a second return airflow duct to the furnace, the second return airflow duct passing through a wall of the first room and into a second room, the second return airflow duct in communication with a return air inlet grille in the second room.

In some configurations, the method may include the step of providing the second return airflow duct with a filter. For example, the second return airflow duct may include a filter rack.

According to another aspect, the step of selecting a furnace with a preexisting return airflow duct comprises selecting a furnace with a preexisting return airflow duct on a first side of the furnace. The step of connecting the second return airflow duct to the furnace may include connecting the second return airflow duct on a second side of the furnace, the second side of the furnace opposite the first side of the furnace.

According to another aspect, the method may include the step of raising the furnace, and the step of connecting the second return airflow duct to the furnace may include connecting the second return airflow duct on a bottom side of the furnace. In some configurations a stand to support the bottom side of the furnace may be provided.

According to another aspect, the step of connecting a second return airflow duct to the furnace may comprise connecting the second return airflow duct to the preexisting return airflow duct.

A process of increasing airflow in an HVAC system may include: measuring current volume in a return air duct; measuring current space allowable for the return air duct; and installing a larger volume return air duct. In some configurations, the step of installing a larger volume return air duct comprises increasing a volume of a preexisting return air duct. In other configurations, the step of installing a larger volume return air duct comprises attaching a second return airflow duct to a furnace. The furnace may be located in a first room, and the second return airflow duct is in communication with a return air inlet grille located in a second room. The process may also include the step of attaching a filter to the second return airflow duct.

In some configurations, the step of attaching a second return airflow duct to the furnace comprises attaching the second return airflow duct on a side of the furnace opposite a side of a preexisting return air duct. In other configurations, the step of installing a larger volume return air duct comprises installing a second return airflow duct to a rooftop HVAC unit.

According to another aspect, a process of increasing airflow in an HVAC system may include the steps of: measuring current volume in a return air duct; measuring current space allowable for the return air duct; and installing a plurality of return air ducts in a plurality of locations. The step of installing the plurality of return air ducts in a plurality of locations may further include installing a first return air duct in communication with a first side of a furnace and installing a second return air duct in communication with a second side of the furnace. In some configurations, the second side is opposite the first side. In other configurations, the second side need not be opposite the first side. In still other configurations, the step of installing a plurality of return air ducts comprises installing at least one return air duct to a rooftop HVAC unit.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate what are currently considered to be specific representative configurations for carrying out the disclosed subject matter and are not limiting as to embodiments which may be made in accordance with the present disclosed subject matter. The components in the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding parts throughout the several views.

The drawings are illustrative and not limiting of the scope of the disclosed subject matter which is defined by the appended claims. The various elements of the disclosed subject matter accomplish various aspects and objects of the disclosed subject matter. Not every element of the disclosed subject matter can be clearly displayed in a single drawing, and as such not every drawing shows each element of the disclosed subject matter.

In the drawings:

FIG. 1 illustrates a return air duct of an HVAC system;

FIG. 2 illustrates the return air duct of FIG. 1 entering a furnace;

FIG. 3 illustrates a filter portion of the HVAC system of FIG. 1;

FIG. 4 illustrates a modified HVAC system;

FIG. 5 illustrates the added air intake of the modified HVAC system of FIG. 4;

FIG. 6 illustrates the intake grille in communication with the added air intake of FIG. 5;

FIG. 7 is a schematic view of an added air intake of FIG. 4;

FIG. 8 illustrates another exemplary modified HVAC system;

FIG. 9 illustrates the added air intake of the modified HVAC system of FIG. 8; and

FIG. 10 illustrates the intake grille in communication with the added air intake of FIG. 9.

DESCRIPTION

The following provides a detailed description of particular embodiments of the present disclosed subject matter. Reference will now be made to the drawings in which the various elements of the illustrated configurations will be given numerical designations and in which the disclosed subject matter will be discussed to enable one skilled in the art to make and use the subject matter. It is to be understood that the following description is only exemplary of the principles of the present disclosed subject matter, and should not be viewed as narrowing the scope of the claims which follow, which claims define the full scope of the disclosed subject matter.

It will be appreciated that various aspects discussed in one drawing may be present and/or used in conjunction with the embodiment shown in another drawing, and each element shown in multiple drawings may be discussed only once. For example, in some cases, detailed description of well-known items or repeated description of substantially the same configurations may be omitted. The reason is to facilitate the understanding of those skilled in the art by avoiding the following description from being unnecessarily redundant. The accompanying drawings and the following description are provided in order for those skilled in the art to fully understand the present disclosure, and these are not intended to limit the gist disclosed in the scope of claims.

Reference in the specification to “one configuration” “one embodiment,” “a configuration” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the configuration is included in at least one configuration, but is not a requirement that such feature, structure or characteristic be present in any particular configuration unless expressly set forth in the claims as being present. The appearances of the phrase “in one configuration” in various places may not necessarily limit the inclusion of a particular element of the disclosed subject matter to a single configuration, rather the element may be included in other or all configurations discussed herein.

The following disclosure and description sets forth the process for increasing the airflow and efficiency of an HVAC system, including utilizing larger return air ducts and adjusting filtration to provide for a higher efficiency system. The process may be implemented in both commercial and residential buildings and may be installed in new buildings or retrofitted into existing buildings.

FIGS. 1 and 2 illustrate a ductwork 10 of an HVAC system in a residential application with a return airflow ductwork that enters the furnace 14 or air conditioning unit from an outside wall 12 of a mechanical or utility room where the furnace 14 resides. The return air ductwork 10 may include at least one planar or substantially piece of sheet metal 16 that is installed on or in a wall, and typically between two studs of a wall. The planar piece of sheet metal 16 may act to provide a channel or pathway for air to flow and the drywall, or sheetrock, forms the other side of the channel opposite the planar piece sheet metal 16 and between the studs. It will be appreciated that the planar piece of sheet metal 16 may span multiple studs to provide a larger channel, or if there is a stud in between, multiple small channels for the air to pass through to return to the furnace 14.

Alternatively, a tube of sheet metal 18 may be utilized to interface between a wall with drywall and the tube of sheet metal 18 may terminate at a given wall and then back at the furnace 14. It is intended whether using planar sheet metal or tubular sheet metal to provide the largest possible space to allow more air to return to the furnace. Increasing the internal volume creates stronger and more efficient outputs of the HVAC system.

Modifications to existing HVAC systems may generally include adding a return air grille and any associated ductwork, either connected to the original, preexisting return air ductwork or to the side opposite the original, preexisting return air ductwork. In yet other configurations, a return air grille may be added in another position within the HVAC system. In some configurations there may be little or no room (or ability) to add return air ductwork to the preexisting return air ductwork or to the opposite side, and in these situations the furnace may be raised. A stand may then be built underneath the furnace and a second return air grille may be added to facilitate air movement within the HVAC system.

In some configurations a filter may also be added in communication with the additional return air grille. For example, when a furnace is raised and a stand built underneath, a filter may be added either to the stand, and/or a filter grille may be used in communication with the additional return air grille. This second air filter in communication with the air grille and/or associated additional ductwork may ensure the air in the HVAC system is clean. In configurations where the second return airflow duct is provided on the side of the furnace, a filter may also be added to the side of the furnace to ensure the air is filtered.

By adding an additional intake to the HVAC system, for example by adding second return airflow duct to the furnace, it may make more air available to the blower of the furnace and increase the output of the blower. It may also lower the static pressure of the duct and thereby increase the velocity pressure. For example, in some configurations, an increase of air output of up to 245 percent was observed. Similarly, static pressure of the duct was found to be lowered below 0.62 and even down to 0.011 (measured before the blower) after adding a second return airflow duct and associated grille to the HVAC system. Thus, providing a static pressure drop anywhere from 0.01 to 0.61.

When modifying HVAC systems the blower motor electrical limits should not be exceeded so the life of the motor and relay board are not compromised. Furnace blowers have different requirements, as each is different and its blower capacity is different. The increase of airflow may be accomplished by either increasing existing return air ducts in size, and/or installing additional return air ducts, providing the same volume but in two different return air ducts. In a residential application this may be provided by accessing the air outside the mechanical room. Because systems are different, each system requires its own analysis and remedy. While a separate duct system can be added to facilitate the desired output, the existing ducts can also sometimes be altered to achieve the desired output. And in some circumstances the supply duct may also be insufficient to deliver air to grilles.

In commercial applications, increased airflow may be accomplished by installing new return air ductwork connecting directly to a rooftop unit (if applicable) or by return to the return air trunk lines. By increasing the return air ducts or adding additional return air ducts, the increases in airflow outputs of the system may be from 0.25 times better to four times better. The increase in air flow is directly reflective by the increase in cubic inches of the return air by the following:

$F = \frac{\left( {C - P} \right)}{P}$

Where F is the change in airflow, C is the current or present cubic inches of the return air duct, and P is the previous or past cubic inches of the return air duct. The increase in airflow may also be calculated using this equation where C is in cubic centimeters and P is in cubic centimeters.

Referring to FIG. 3, an air filter system 20 is depicted with a filter 22. The return airline 10 enters the furnace at an angle between 30° and 45° which provides greater air flow efficiency. It will be appreciated that any angle may be utilized from 0° to 90°. The process of moving the filter system 20 to an angle between 30° and 45° allows for increased flow with reduced resistance and may allow for use of a larger air filter than may have been previously contemplated.

The process of installing additional return air ducts may provide increased benefits and heating and cooling efficiencies in the building as well. Ideally installing a return air duct at the lowest possible point in a building may draw the coldest air of the building into the furnace to be heated or cooled. Similarly, installing a return air duct at the highest possible point in a building may draw the warmest air of the building into the furnace to be heated or cooled. These additional return air ducts may provide greater efficiency in each case depending on which air the system is trying to properly put out. The process may also include transfer air ducts that transfer airflow from room to room to provide for even heating and cooling of an entire building.

FIGS. 4-5 shows an exemplary altered furnace in a residential setting with an added second return airflow duct 35. The existing return air duct 30 is shown on the right of the furnace 14. The second return airflow duct 35 is shown attached to the left side of the furnace 14. The second return airflow duct 35 may be in communication with a room apart from the room that the furnace 14 is housed in. For example, the furnace 14 may be housed in a mechanical room 37, and the second return airflow duct 35 may pass through a wall 39 between the mechanical room and a second room 44. The second return airflow duct 35 may be in communication with a return air inlet grille 40 located in a second room 44 (FIGS. 6-7). Additionally, the second return airflow duct may comprise a second filter, and in some configurations the second return airflow duct may comprise a filter rack.

FIGS. 8-9 show another exemplary furnace alteration in a residential setting. The furnace 14′ had an existing return air duct 30′ provided, shown on the left side in FIG. 8. The HVAC system shown was altered by adding a second return airflow duct 35′, as indicated at the right side of the furnace 14′. This second return airflow duct 35′ is a square duct that passes through the wall 39′ that separates the mechanical room 37′ from a second room 44′. Thus, the second return airflow duct 35′ is in communication with a room apart from the room that the furnace 14′ is housed in. The second return airflow duct 35′ is also in communication with a return air inlet grille 40′ located in a second room 44′ (FIG. 10). Additionally, the second return airflow duct 35′ may be provided with a filter.

Although the foregoing disclosure provides many specifics, such as use of the system in heating and cooling systems, other applications are contemplated and these should not be construed as limiting the scope of any of the ensuing claims. Other embodiments and configurations may be devised which do not depart from the scopes of the claims. Features from different embodiments and configurations may be employed separately or in combination. Accordingly, all additions, deletions and modifications to the disclosed subject matter that fall within the scopes of the claims are to be embraced thereby. The scope of each claim is indicated and limited only by its plain language and the full scope of available legal equivalents to its elements.

Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, while the HVAC system set of the present disclosure has been described in connection with particular examples thereof, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and claims that follow. 

What is claimed:
 1. A method for increasing airflow in an HVAC system comprising: selecting a furnace with a preexisting return airflow duct, the furnace located in a first room; connecting a second return airflow duct to the furnace, the second return airflow duct passing through a wall of the first room and into a second room, the second return airflow duct in communication with a return air inlet grille in the second room.
 2. The method of claim 1, further comprising the step of providing the second return airflow duct with a filter.
 3. The method of claim 2, further comprising the step of providing the second return airflow duct with a filter rack, and placing the filter in the filter rack.
 4. The method of claim 1, wherein the step of selecting a furnace with a preexisting return airflow duct comprises selecting a furnace with a preexisting return airflow duct on a first side of the furnace.
 5. The method of claim 4, wherein the step of connecting the second return airflow duct to the furnace comprises connecting the second return airflow duct on a second side of the furnace, the second side of the furnace opposite the first side of the furnace.
 6. The method of claim 4, further comprising the step of raising the furnace, and wherein the step of connecting the second return airflow duct to the furnace comprises connecting the second return airflow duct on a bottom side of the furnace.
 7. The method of claim 6, further comprising the step of providing a stand to support the bottom side of the furnace.
 8. The method of claim 1, wherein the step of connecting a second return airflow duct to the furnace comprises connecting the second return airflow duct to the preexisting return airflow duct.
 9. A process of increasing airflow in an HVAC system comprising: measuring current volume in a return air duct; measuring current space allowable for the return air duct; and installing a larger volume return air duct.
 10. The process of claim 9, wherein the step of installing a larger volume return air duct comprises increasing a volume of a preexisting return air duct.
 11. The process of claim 9, wherein the step of installing a larger volume return air duct comprises attaching a second return airflow duct to a furnace.
 12. The process of claim 11, wherein the furnace is located in a first room, and wherein the second return airflow duct is in communication with a return air inlet grille located in a second room.
 13. The process of claim 12, further comprising the step of attaching a filter to the second return airflow duct.
 14. The process of claim 11, wherein the step of attaching a second return airflow duct to the furnace comprises attaching the second return airflow duct on a side of the furnace opposite a side of a preexisting return air duct.
 15. The process of claim 9, wherein the step of installing a larger volume return air duct comprises installing a second return airflow duct to a rooftop HVAC unit.
 16. A process of increasing airflow in an HVAC system comprising: measuring current volume in a return air duct; measuring current space allowable for the return air duct; installing a plurality of return air ducts in a plurality of locations; and increasing volume of the airflow through the plurality of air ducts.
 17. The process of claim 16, wherein the step of installing the plurality of return air ducts in a plurality of locations comprises installing a first return air duct in communication with a first side of a furnace and installing a second return air duct in communication with a second side of the furnace.
 18. The process of claim 17, wherein the second side is opposite the first side.
 19. The process of claim 16, further comprising the step of installing a filter at each of the plurality of return air ducts.
 20. The process of claim 16, wherein the step of installing a plurality of return air ducts comprises installing at least one return air duct to a rooftop HVAC unit. 